Method of forming rigid package structure



March 8, 1966 R. v. BURT METHOD OF FORMING RIGID PACKAGE STRUCTURE 3 Sheets-Sheet 1 Filed Dec.

FIG-I FIG2 FIG 3 INVENTOR. ROBERT V. BURT MW FIG-6 ATTORNEY March 8, 1966 v, -r

METHOD OF FORMING RIGID PACKAGE STRUCTURE 3 Sheets-Sheet 2 Filed Dec.

ROBERT V. BURT BY M A! 3,

ATTORNEY March 8, 1966 R. v. BURT 3,238,693

, METHOD OF FORMING RIGID PACKAGE STRUCTURE Filed Dec. 10, 1962 3 Sheets-Sheet 5 i, Inna INVENTOR. ROBERT V. BURT AITO RN EY United States Patent F 3,238,693 METHOD OF FORMING RIGID PACKAGE STRUCTURE Robert V. Burt, Cincinnati, Ohio, assignor to The Procter & Gamble Company, Cincinnati, Skin, a corporation of Ohio Filed Dec. 10, 1962, Ser. No. 243,294 3 Claims. (CI. 53-29) This invention relates to package forming methods. More particularly it relates to a method of forming a channel strip of paperboard or like material, wrapping the channel strip around an article, and thereafter joining its ends to complete a channel frame pack-age.

It is an object of the present invention to provide a method of forming a rigid package structure of the type illustrated and described in the co-pending application of Robert V. Burt, Serial No. 242,730, filed on December 6, 1962, now U. S. Patent 3,159,274 dated December 1, 1964 which is commonly owned by the assignee of the present application.

Another object of the invention is the provision of a method of forming a rigid channel frame around objects having convex surfaces and articles of irregular shape, said method being commercially feasible for high production rates with a minimum of manipulation.

The nature and substance of the invention can be summarized briefly as comprising the steps of forming a channel strip composed of a plurality of panels having tubular supports on their inside surfaces at the upper and lower edges. A bar of soap or other article to be wrapped is held between a pair of opposed holders. One of the panels of the channel strip is moved against the article so that the tubular supports engage the edge of the article on opposite sides. The frame is thereafter formed around the article until four sides of the article are enclosed by the panels and tubular supports. The ends of the channel strip are thereafter joined to complete the package.

While the method of this invention is well suited for packaging articles of any shape, it will be referred to herein as applied to bar soap packaging. The invention has been found to have particular wide utility and application in this field. It will be understood, of course, that this is not to be construed as a limitation on the invention as the packaging of toothpaste tubes, shampoo containers, hairdressing containers and like articles are well within the contemplation of the inventive concept hereinafter disclosed and claimed.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed the invention will be better understood from the following description taken in connection with the accompanying drawings in which:

FIGURE 1 is a plan view of a frame blank in flat form.

FIGURE 2 is a plan view of the frame blank after the tubular supports have been formed into a channel strip.

FIGURE 3 is an end view of FIGURE 2 showing the tubular supports in elevation.

FIGURE 4 is an end elevation showing an alternate method of forming the tubular supports with the frame blank of FIGURE 1.

FIGURE 5 is a perspective view showing schematically a series of manipulative steps for forming the package.

FIGURE 6 is a fragmentary plan view of a modified end tab configuration on the frame blank.

FIGURE 7 is a perspective view showing schematically another series of manipulative steps for forming the completed package.

Patented Mar. 8, 1966 Referring now to the drawings and particularly FIG- URE 1 there is shown a frame blank 19 which is formed by cutting and scoring cardboard, paperboard, cartonboard or like material. The frame blank is divided into end panels 20 and 21, side panels 22 and 23 and a glue flap 24 by means of the horizontal scores 25 and 26 and the vertical scores 27, 28, 29, and 30.

Each of the panels 20 through 23 have an extending portion 31 at the top and an extending portion 32 at the bottom. Each of the extending portions 31 are divided into three parallel areas by the horizontal scores 33 and 34, the score 33 being aligned on each of the extending portions 31 and, similarly, the score 34 being aligned on each of the extending portions 31. The lower extending portions 32 are similarly divided by horizontal scores 35 and 36.

The extending portions 31 are separated by slots 37 which extend outwardly in parallel relation from the horizontal score 34. Each slot 37 is beveled at 38 and 39 at an angle of about 30 running from the horizontal score 34 inwardly to intersect at the horizontal score 2 5 and the respective vertical scores 28, 29 and 30.

A bevel 40 of about 30 extends from the intersection of the horizontal score 25 and the vertical score 27 to the horizontal score 34. The left edge 41 of the upper portion 31 extending from the end panel 20 is substantially perpendicular to the scores 33 and 34 outwardly of the score 34. The right edge of the upper extending portion 31 from the side panel 23 is for-med with a substantially 30 bevel 42 from the intersection of the horizontal score 25 with the end edge 43 to the horizontal score 34. The right edge 44 of the upper portion 31 extending from the side panel 23 is substantially perpendicular to the scores 33 and 34 outwardly of the score 34.

The lower extending portions 32 are congruent with each of the upper extending portions 31 of their respective panels 20, 21, 22 and 23.

The blank of FIGURE 1 is next folded and formed into a channel strip configuration 52a as illustrated in FIG- URES 2 and 3. Each upper extension 31 is folded so that its outer area 45 (beyond the score 33) is contiguous to its respective panel 20, 21, 22 or 23. The length of each extension 31 is such that in so doing the intermediate area 46 (between the scores 33 and 34) and the inner area 47 (between the scores 25 and 34) from an inwardly extending reinforcing tubular support 48 along the upper edge of each panel 20, 21, 22, and 23. Similarly, each lower extension 32 is folded so that its outer area 49 is contiguous with its respective panel 20, 21, 22 and 23. In so doing, the intermediate areas 50 and the inner areas 51 form an inwardly extending tubular support 52 along the lower edge of each panel 20, 21, 22 and 23.

The areas 45 and 49 which lie against the panels 20, 21, 22 and 23 are preferably adhered thereto by any well known adhesive as at 53 (FIGURE 3). In some case-s, however, the package can be formed without adhering the areas 45 and 49 to the panels.

The tubular supports 48 and 52 add substantially to the rigidity of the channel strip 52a as hollow structural members. While they are described and illustrated herein as being of substantially triangular configuration, this configuration can be altered by the manner in which the extensions 31 and 32 are scored and formed. The tubular supports 48 and 52 can be formed in half-round, rectangular or other geometric configurations as will be understood by those skilled in the art.

One modification for forming the tubular supports 48 and 52 is shown in FIGURE 4. The areas 45 and 49 are folded under the tubular supports so that their ends are about in line with the scores 25 and 26, respectively,

3 and adhesive may be applied at the points 54 in order to keep the channel strip in the folded condition.

The formed channel strip 52a of FIGURE 2 which may, if desired, be in the cross section of FIGURE 3 or FIG- URE 4 is now ready for manipulation into a rigid pack-age structure by being formed around an article which for exemplary purposes will be described as a bar of soap 55. The left end of FIGURE 5 shows a bar of soap 55 clamped lightly between a pair of holders 56 and 57. The channel frame 52a of FIGURE 2 is moved into the path of the bar 55 so that the side panel 22 is aligned with one side surface of the bar 55. The bar moves forward in the direction of the arrows carrying with it the formed channel strip 52a. In doing so, the glue flap 24 passes under a glue applying wheel 57a.

As the bar 55 is moved forward, it passes between the stationary folding bars 58 and 59 which form the panels 20 and 21 around the ends of the bar. Further movement of the bar and channel strip 52a continues until the combination is alongside the tucker member 60 which is pivoted at 61. The tucker member 60 folds the side panel 23 against the trailing edge of the bar 55 so that it is enclosed on four sides. The tucker member 62 pivoted at 63 then swings around and forces the end of the panel 23 against the glue flap 24. The notch 64 in the tucking member 62 holds the panel 23 against the glue flap 24 for a sufiicient time interval to adhere the ends of the channel strip 52a and complete its formation around the bar.

After being formed by the above described procedure, the frame is snugly engaged around the bar 55 as the tubular supports 48 and 52 hold the bar firmly within the frame whereby a rigid package structure is formed. The holders 56 and S7 thereafter move the package and article over the take-away belts 65 and 66, depositing the package and article thereon and then moving away from the package and article so that the belts can move the package to any further wrapping or other manipulative procedures. For example, an outer wrapper can thereafter be formed around the frame by means of the apparatus described and claimed in the copending application of Charles R. Hood, Serial No. 126,998, filed July 26, 1961, now US. Patent 3,149,446 dated September 22, 1964 which is commonly owned by the assignee of the present invention.

FIGURE 6 illustrates a slightly modified version of the channel strip 52a of FIGURE 2. In FIGURE 6, the glue flap 24 has been replaced by an end tab 67 with extending tongues 68 and 69. The purpose of the modified tab structure is to permit the formation of the frame around the bar of soap without the need for gluing as the tongues 68 and 69 can be inserted within the hollows of the tubular supports 48 and 52. A method of forming the package wit-h this modified tab structure will now be described.

Referring to FIGURE 7, the bar 55 is held between an upper gripper 70 the lower surface of which conforms substantially to the contour of the bar and a lower gripper 71 which is substantially smaller in area than the upper gripper. A nipper member 72 is pivoted to the upper gripper 70 around the pin 73. A spring 73a is provided to normally bias the end 72a of the nipper member 72 toward the bar 55. A nipper cam rail 74 is provided to pivot the nipper member 72 so that its end 72a is initially swung out from the bar 55.

The channel strip 52a as formed in FIGURE 2 but with the end tab 67 of FIGURE 6 is fed by means of the forwarding wheels 75 and 76. The forwarding wheels 75 and 76 feed the channel strip 52a so that the panel 20 is moved alongside one side of the bar 55. As the grippers 70 and 71 move forward in the direction of the arrows along with the channel strip 52a, the nipper 72 moves beyond the end of the rail 74 whereby the spring 73a causes the nipper end 72a to hold the panel 20 against the side surface of bar 55.

The upper and lower grippers 70 and 71 continue to carry the bar 55 and channel strip 520 forward past a stationary folder rail 78 having an inwardly extending end 79. As the grippers move alongside the rail 78, the grippers are rotated, causing the successive panels 20, 22, 21 and 23 to be formed entirely around the edges of the bar 55. As the panel 23 moves past the end 79 of the rail 78, it is moved into engagement with the end tab 67 so that the tongues 68 and 69 enter the inside of the tubular support channels 48 and 52.

The gripper members 70 and 71 then carry the completed package over the take-away belts 80 and 81. The finished package 82 is deposited on the take-away belts 80 and 81 and the gripper members 70 and 71 move apart so that the belts control the further movement of the finished package to any subsequent operations and further manipulative steps.

While particular embodiments of the invention have been illustrated and described it will be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention and it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

What is claimed as new is:

1. A method of forming a rigid package structure comprising the steps of forming a frame from a frame blank generally configured in the form of an elongated strip of paperboard material, impressing two spaced parallel score lines on said frame blank running longitudinally from one end of said elongated strip to the other end thereof, impressing a plurality of transverse score lines at intervals along the said frame blank substantially perpendicular to said parallel longitudinal score lines thereby dividing the central portion of the frame blank into at least four wall forming panels including two side panels and two end panels, said side and end panels being alternately spaced along said frame blank, forming extending portions projecting laterally outwardly from each of the longitudinal score lines which define the edge portions of said panels, cutting angular relief cut-outs outwardly of each of said transverse score lines to at least partially separate each of said extending portions, forming a channel strip by folding each of said extending portions into a tubular support, adhering said tubular supports to their adjoining panels so that each of said side and end panels has a pair of spaced, substantially rigid tubular supports in parallel relationship alongside the longitudinal score lines forming the upper and lower extremities of said side and end panels to complete said channel strip, clamping an article and moving it forward, placing said channel strip in the path of said article so that one of said wall forming panels is aligned with the path of movement of one edge surface of said article, moving the edge surface of the article against said one of said wall forming panels and thereafter carrying forward the article and the channel strip in assembled relationship, folding the two wall forming panels adjoining the said one of said wall forming panels against the ends of the article so they are at substantially right angles to the said one of said wall forming panels, folding the remaining wall forming panel into contiguous relationship with the trailing edge of the article so that the article is enclosed and surrounded on four sides by a frame structure.

2. A method of forming a rigid package structure comprising the steps of forming a frame from a frame blank generally configured in the form of an elongated strip of paperboard material, impressing two spaced parallel score lines on said frame blank running longitudinally from one end of said elongated strip to the other end thereof, impressing a plurality of transverse score lines at intervals along the said frame blank substantially perpendicular to said parallel longitudinal score lines thereby dividing the central portion of the frame blank into at least four wall forming panels including two side panels and two end panels, said side and end panels being alternately spaced along said frame blank, forming extending portions projecting laterally outwardly from each of the longitudinal score lines which define the edge portions of said panels, cutting angular relief cut-outs outwardly of each of said transverse score lines to at least partially separate each of said extending portions, forming a channel strip by folding each of said extending portions into a tubular support, adhering said tubular supports to their adjoining panels so that each of said side and end panels has a pair of spaced, substantially rigid tubular supports in parallel relationship alongside the longitudinal score lines forming the upper and lower extremities of said side and end panels to complete said channel strip, holding an article between a pair of grippers, forwarding the channel strip to the pair of grippers, holding one of the four wall forming panels against one edge surface of the article, moving the article and channel strip forward in unison, rotating the article to cause the successive wall forming panels to be formed around the article and to complete the frame structure around the article.

3. A method of forming a rigid package structure comprising the steps of forming a frame from a frame blank generally configured in the form of an elongated strip of paperboard material, impressing two spaced parallel score lines on said frame blank running longitudinally from one end of said elongated strip to the other end thereof, impressing a plurality of transverse score lines at intervals along the said frame blank substantially perpendicular to said parallel longitudinal score lines thereby dividing the central portion of the frame blank into at least four wall forming panels including two side panels and two end panels, said side and end panels being alternately spaced along said frame blank, forming extending portions projecting laterally outwardly from each of the longitudinal score lines which define the edge portions of said panels, cutting angular relief cut-outs outwardly of each of said transverse score lines to at least partially separate each of said extending portions, forming a channel strip by folding each of said extending portions into a tubular support, adhering said tubular supports to their adjoining panels so that each of said side and end panels has a pair of spaced, substantially rigid tubular supports in parallel relationship alongside the longitudinal score lines forming the upper and lower extremities of said side and end panels to complete said channel strip, supporting an article and moving it forward, placing said chan nel strip in the path of said article so that one of said wall forming panels is aligned with the path of movement of one edge surface of said article, moving the edge surface of the article against said one of said wall forming panels and thereafter carrying forward the article and the channel strip in assembled relationship, folding the two wall forming panels adjoining the said one of said wall forming panels against the ends of the article so they are at substantially right angles to the said one of said wall forming panels, folding the remaining wall forming panel into contiguous relationship with the trailing edge of the article so that the article is enclosed and surrounded on four sides by a frame structure.

References Cited by the Examiner UNITED STATES PATENTS 2,395,558 2/ 1946 Lighter 20645.31 2,450,110 9/1948 Brooks 22934 2,713,453 7/1955 Williamson 206-45.3l XR 3,082,864 3/1963 Silver 20645.31 XR FRANK E. BAILEY, Primary Examiner.

TRAVIS S. MCGEHEE, Examiner. 

1. A METHOD OF FORMING A RIGID PACKAGE STRUCTURE COMPRISING THE STEPS OF FORMING A FRAME FROM A FRAME BLANK GENERALLY CONFIGURED IN THE FORM OF AN ELONGATED STRIP OF PAPERBOARD MATERIAL, IMPRESSING TWO SPACED PARALLEL SCORE LINES ON SAID FRAME BLANK RUNNING LONGITUDINALLY FROM ONE END OF SAID ELONGATED STRIP TO THE OTHER END THEREOF, IMPRESSING A PLURALITY OF TRANSVERSE SCORE LINES AT INTERVALS ALONG THE SAID FRAME BLANK SUBSTANTIALLY PERPENDICULAR TO SAID PARALLEL LONGITUDINAL SCORE LINES THEREBY DIVIDING THE CENTRAL PORTION OF THE FRAME BLANK INTO AT LEAST FOUR WALL FORMING PANELS INCLUDING TWO SIDE PANELS AND TWO END PANELS, SAID SIDE AND END PANELS BEING ALTERNATELY SPACED ALONG SAID FRAME BLANK, FORMING EXTENDING PORTIONS PROJECTING LATERALLY OUTWARDLY FROM EACH OF THE LONGITUDINAL SCORE LINES WHICH DEFINE THE EDGE PORTIONS OF SAID PANELS, CUTTING ANGULAR RELIEF CUT-OUTS OUTWARDLY OF EACH OF SAID TRANSVERSE SCORE LINES TO AT LEAST PARTIALLY SEPARATE EACH OF SAID EXTENDING PORTIONS, FORMING A CHANNEL STRIP BY FOLDING EACH OF SAID EXTENDING PORTIONS INTO A TUBULAR SUPPORT, ADHERING SAID TUBULAR SUPPORTS TO THEIR ADJOINING PANELS SO THAT EACH OF SAID SIDE AND END PANELS HAS A PAIR OF SPACED, SUBSTANTIALLY RIGID TUBULAR SUPPORTS IN PARALLEL RELATIONSHIP ALONGSIDE THE LONGITUDINAL SCORE LINES FORMING THE UPPER AND LOWER EXTREMITIES OF SAID SIDE AND 